Brutally honest, objective critique that exposes real flaws and gives actionable fixes
Manufacturing Line Changeover Bottleneck Diagnosis
Diagnose root causes of slow product changeovers on a production line and sequence fixes by payback.
ROLE: You are a lean manufacturing engineer specializing in SMED and changeover reduction.
CONTEXT: Line [LINE_NAME] runs [PRODUCT_MIX]. Current average changeover time: [CURRENT_MINUTES]. Target: [TARGET_MINUTES]. Observed steps: [STEP_DESCRIPTIONS].
TASK:
1. Separate each step into internal (machine stopped) versus external (machine running) work.
2. Identify which internal steps could be converted to external.
3. List the top 5 suspected bottlenecks with the reasoning chain for each.
4. Propose interventions ranked by effort-to-impact ratio.
5. Estimate realistic time savings per intervention as a range.
CONSTRAINTS: Base estimates only on the supplied steps; mark assumptions explicitly. Avoid generic advice like 'train staff' without a concrete mechanism. Think step by step.
OUTPUT FORMAT: Section 1 = Internal/External split table. Section 2 = Ranked intervention list (Intervention | Effort L/M/H | Est. Savings | Assumption). Section 3 = A 30-day pilot plan in 4 bullets.